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Customised Gasifier Feed Pumps
Daniel M. NägelFELUWA Pumpen GmbHNaegeld@feluwa.de
Copyright FELUWA Pumpen GmbH
Hydrostatic displacement Pumps
Oscillating Pumping Characteristic
Piston Pump Diaphragm Piston PumpThe conveyed fluid is in contact Hermetically sealed! The conveyed fluid is in contact with sliding seals
Hermetically sealed! The conveyed fluid is not in contact with sliding seals
1
27 8 9
611
3
3
7 8 9
45
6 412 13 1410VL = Leckagevolumen
1. Pressure air vessel2. Safety valve3 Discharge valve
6. Conveyed fluid7. Piston seal8 Piston
11. Hydraulik oil12. Plunger13 Plunger seal
Copyright FELUWA Pumpen GmbH2 Heinz M Nägel
3. Discharge valve4. Suction valve5. Suction air vessel
8. Piston9. Crank shaft10. Diaphragm
13. Plunger seal14. Crosshead
E 2201190
Traditional hydraulically actuated Process Pumps
Typical diaphragm clamping(risk of sedimentation and damaging in the clamping area)
Hydraulically actuated diaphragm pump
Disadvantage:The utilisation of traditional diaphragm pumps is limited when it comes to the handling of
lid i fl id I th t f di h f il th d fl id ill t tsolids-carrying fluids. In the event of a diaphragm failure the conveyed fluid will penetrateinto the hydraulic drive end and come in contact with sliding seals and the cylinder face,which in turn results in considerable damaging (cost!).
Copyright FELUWA Pumpen GmbH3 Heinz M NägelE 2103037-2
Traditional Double Diaphragm Piston Pump
In order to get rid of the hidden danger in the first generation diaphragm pumps, FELUWA tried to developed a kind of double diaphragm pumps as shown aboveFELUWA tried to developed a kind of double-diaphragm pumps, as shown above.
This design concept ist good, but it can not solve the problem fundamentally. The two diaphragms have the same shape and are installed in the same way. When one
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p g p yof them is broken, the other one will be worn out soon.
Heinz M Nägel
Stresses of Double Flat Diaphragms
1,00
0,83
0,67
0 500,50
0,33
0,17
0,00
Copyright FELUWA Pumpen GmbH5 Heinz M NägelNo E 2201171-4
Evolution of PumpsMULTISAFE Hose Diaphragm PumpMULTISAFE Hose-Diaphragm Pump
Outlet Outlet
Piston in rear position Piston in front position=
End of suction stroke=
End of discharge stroke
Piston Piston
Inlet Inlet
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MULTISAFE Double Hose Diaphragm PumpBionics in the construction of pumps
Inner Outer
Bionics in the construction of pumps
Inner hose‐diaphragm
Outerhose‐diaphragm Hydraulic load onto
hose-diaphragms
Hydrostatic pressure by means ofsurrouding hydraulic fluidg y
• Identical pressure inside and outside of the hose‐diaphragmo t e ose d ap ag
• The hose‐diaphragm is not subject tophysical load, but to static load only
The conveyed fluid is in contact with thehose‐diaphragm only
Incompressible coupling fluid between both hose‐
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Hydraulic fluid diaphragms (compatible to the conveyed fluid)
Stresses of Double Hose-Diaphragms
1 000 830 670 500 330 170 00 1,000,830,670,500,330,170,00
Copyright FELUWA Pumpen GmbH8 Heinz M NägelNo E 2201171-2
Customised Gasifier Feed Pumps
Other significant features of FELUWA double hose diaphragm pumps
Ch k l
double hose-diaphragm pumpsHose failure monitoring
As shown in the photo on the left side, Check valve
Pressure switch
the gap between the inner and the outer
hoses is connected to a pressure switch.
Before the pump is put into operation, switchthe gap is to be filled with liquid to get
rid of air. When the pump is started up,
air and liquid are vented and drained air and liquid are vented and drained
from the air venting valve with the pressure
increase in the pump head. At this time,
th i i th b t th there is no pressure in the gap between the
two hoses. When any of them is broken,
the pressure inside the gap will go up,
Vent valve
then the pressure switch will give out an alarm.
Such a hose failure alarming system is very
sensitive, instant and reliable.
Copyright FELUWA Pumpen GmbH9No E 2140125 Heinz M Nägel
Customised Gasifier Feed Pumps
Valves
Necessity of Double Valves
Copyright FELUWA Pumpen GmbH10
Ball Valve vs. Cone Valve
Ball Valve Cone ValveBall Valve Cone ValveGuide bush
Cone top
Compression i
guideValve ball
Ball guide
spring
Rubber ring
Valve seat (reversible) Cone
Cone valve disc
( )Valve seat
Co eguide
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Unexpected Particles and Foreign Matters Found in Regular Coal SlurryFound in Regular Coal Slurry
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Special Configurations- Double Valves -- Double Valves -
• Double valves are used for critical processes which do not allow interrupted flow.
• Double valves provide double safety against smallest leakages.
• Double valves reduce valve wear and increase maintenance intervals.
Copyright FELUWA Pumpen GmbH13E 23100016 Heinz M Nägel
Customised Gasifier Feed Pumps
Pump Speed
Copyright FELUWA Pumpen GmbH14
Wear Related to Speed
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Characteristics of displacement Pumps
Single-acting one-cylinderSingle acting one cylinder pump
Double-acting one-cylinder pump
Three-cylinder pump
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Unique pulsation dampener- Kinematic Irregularity -
FELUWA PULSORBER +
- Kinematic Irregularity -
FELUWA PULSORBER + (PULSORBER with integrated air vesseland automatic filling
Solenoid valve (v1)
Solenoid valve (v2)g
device)
Provides optimum Air outlet
Hose-diaphragm
Compressed airClient’s compressed
kprotection against water hammer.
Hose-diaphragm condition monitoring
Gas cushion
air network
Bladder type Level indicator
FELUWA hose-diaphragm pulsation dampener
Bladder-type accumulator
pulsation dampener
Double hose-diaphragm
Actuation fluid
Fluctuating hydraulic fluid
Actuation fluidMedium
Discharge pipe
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Permanent monitoring of all Permanent monitoring of all components and operating parameters that are relevant to functioningg
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Quintuplex MULTISAFE Process PumpsPermanent Operation MonitoringPermanent Operation Monitoring
Operation Monitoring: The detection of inadmissible d f d dd
Option: Automatic behaviouroperating conditions safe guards against sudden failure.
Pre‐Compression
Hydraulic Temperature
under alarm condition
Hydraulic Temperature
Suction Pressure !
LocalMonitoring System
DCSTemerature of Flow of Gearbox Oil
R tSIEMATICFreq enc
Motor Temperature
Temerature and Flow of Intermediate Gearbox Oil
Copyright FELUWA Pumpen GmbH19Foliennr
RemoteService
SIEMATICS7‐300
FrequencyConverter
Quintuplex MULTISAFE Process PumpsPermanent Operation and Condition Monitoring of all Components thatare relevant to Fuctioning
Condition Monitoring: The detection of incipient wear f i l i d i d
Valve Wearof typical wearing parts reduces maintenance cost and increase life span. Option: Automatic
behaviour underalarm condition.alarm condition.
LocalMonitoring System
DCS
Hose‐Diaphragm
R tSIEMATICFreq enc
Hose Diaphragm
Copyright FELUWA Pumpen GmbH20Foliennr
RemoteService
SIEMATICS7‐300
FrequencyConverter
Customised Gasifier Feed Pumps
COAL GASIFICATIONHigh Pressure Gasifier FeedingHigh Pressure Gasifier Feeding
Configuration Optionsg p
Copyright FELUWA Pumpen GmbH21
COAL GASIFICATION - Configuration Options2 Gasifiers - 4 Burner System 2 Gasifiers - 4 Burner System
1 2
Pump Q p PUnits m³/h MPa kW4 31‐63 7.2 250
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FELUWA Quadruplex HDP ZGL 300/250 –2 K 180 – 4 SM 460 HD
No E 2201168-5
FELUWA HDP Hose-Diaphragm and MULTISAFE Pumps with FHDP Pulsation Dampener for Coal Gasification FHDP Pulsation Dampener for Coal Gasification
Front: FELUWA Hose Diaphragm Pump ZGL 300/250-2K 180-4SM 460 HD
Copyright FELUWA Pumpen GmbH23No E 2171010-1
Rear: FELUWA MULTISAFE Process Pump TGK 400/400 – K 150 – DS 100 HD-U
COAL GASIFICATION - Configuration Options2 Gasifiers - 1 Burner System 2 Gasifiers - 1 Burner System
12
AB
P0201 AP0201 B
Pump Q p PUnits m³/h MPa kW3 15 – 69 7.2 132
Copyright FELUWA Pumpen GmbH24No E 2201168-1
Triplex FELUWA MULTISAFE TG 180/200 – K 180 – DS 100 HD
FELUWA MULTISAFE Hose-Diaphragm Pumps with PULSORBER Pulsation Dampener for Coal Gasification PULSORBER Pulsation Dampener for Coal Gasification
T i l FELUWA H Di h P ZGL 300/250 2K 180 4SM 460 HD
Copyright FELUWA Pumpen GmbH25
Triplex FELUWA Hose Diaphragm Pump ZGL 300/250-2K 180-4SM 460 HD
FELUWA Pumps in Coal Gasification Industry
• In China, a high number of coal gasification plants are used to produce syngas.p y g
• Nowadays, FELUWA’s share of reactor feeding pumps is about 90%.• The coal gasification plants are operated with a total of 361 FELUWA
pumps• With an overall driving power of 70,135 kW, they are pumping a total
volume of 14,491 m³ coal slurry per hour at pressures up to 100 bar
• By means of the FELUWA pumps, 575 million cubic meters of syngas (in terms of CO2 and H) are produced per day ) p p y
The pumps are regarded as the most important item within the plant and none of them has ever caused an
emergency shutdown of the facility.
Copyright FELUWA Pumpen GmbH26E 2102023-11
Thank you for your attention - Questions?
Dipl -Ing Daniel M Naegel
Copyright FELUWA Pumpen GmbH
Dipl. Ing. Daniel M. Naegel nageld@feluwa.de